Classifications

• • C—CHEMISTRY; METALLURGY
  • C08—ORGANIC MACROMOLECULAR COMPOUNDS; THEIR PREPARATION OR CHEMICAL WORKING-UP; COMPOSITIONS BASED THEREON
  • C08L—COMPOSITIONS OF MACROMOLECULAR COMPOUNDS
  • C08L23/00—Compositions of homopolymers or copolymers of unsaturated aliphatic hydrocarbons having only one carbon-to-carbon double bond; Compositions of derivatives of such polymers
  • C08L23/02—Compositions of homopolymers or copolymers of unsaturated aliphatic hydrocarbons having only one carbon-to-carbon double bond; Compositions of derivatives of such polymers not modified by chemical after-treatment
  • C08L23/10—Homopolymers or copolymers of propene
  • C08L23/14—Copolymers of propene
• • C—CHEMISTRY; METALLURGY
  • C08—ORGANIC MACROMOLECULAR COMPOUNDS; THEIR PREPARATION OR CHEMICAL WORKING-UP; COMPOSITIONS BASED THEREON
  • C08F—MACROMOLECULAR COMPOUNDS OBTAINED BY REACTIONS ONLY INVOLVING CARBON-TO-CARBON UNSATURATED BONDS
  • C08F2/00—Processes of polymerisation
• • C—CHEMISTRY; METALLURGY
  • C08—ORGANIC MACROMOLECULAR COMPOUNDS; THEIR PREPARATION OR CHEMICAL WORKING-UP; COMPOSITIONS BASED THEREON
  • C08F—MACROMOLECULAR COMPOUNDS OBTAINED BY REACTIONS ONLY INVOLVING CARBON-TO-CARBON UNSATURATED BONDS
  • C08F4/00—Polymerisation catalysts
  • C08F4/42—Metals; Metal hydrides; Metallo-organic compounds; Use thereof as catalyst precursors
  • C08F4/44—Metals; Metal hydrides; Metallo-organic compounds; Use thereof as catalyst precursors selected from light metals, zinc, cadmium, mercury, copper, silver, gold, boron, gallium, indium, thallium, rare earths or actinides
  • C08F4/60—Metals; Metal hydrides; Metallo-organic compounds; Use thereof as catalyst precursors selected from light metals, zinc, cadmium, mercury, copper, silver, gold, boron, gallium, indium, thallium, rare earths or actinides together with refractory metals, iron group metals, platinum group metals, manganese, rhenium technetium or compounds thereof
  • C08F4/62—Refractory metals or compounds thereof
  • C08F4/64—Titanium, zirconium, hafnium or compounds thereof
• • C—CHEMISTRY; METALLURGY
  • C08—ORGANIC MACROMOLECULAR COMPOUNDS; THEIR PREPARATION OR CHEMICAL WORKING-UP; COMPOSITIONS BASED THEREON
  • C08K—Use of inorganic or non-macromolecular organic substances as compounding ingredients
  • C08K5/00—Use of organic ingredients
  • C08K5/0008—Organic ingredients according to more than one of the "one dot" groups of C08K5/01 - C08K5/59
  • C08K5/0083—Nucleating agents promoting the crystallisation of the polymer matrix
• • C—CHEMISTRY; METALLURGY
  • C08—ORGANIC MACROMOLECULAR COMPOUNDS; THEIR PREPARATION OR CHEMICAL WORKING-UP; COMPOSITIONS BASED THEREON
  • C08L—COMPOSITIONS OF MACROMOLECULAR COMPOUNDS
  • C08L23/00—Compositions of homopolymers or copolymers of unsaturated aliphatic hydrocarbons having only one carbon-to-carbon double bond; Compositions of derivatives of such polymers
  • C08L23/02—Compositions of homopolymers or copolymers of unsaturated aliphatic hydrocarbons having only one carbon-to-carbon double bond; Compositions of derivatives of such polymers not modified by chemical after-treatment
  • C08L23/10—Homopolymers or copolymers of propene
  • C08L23/14—Copolymers of propene
  • C08L23/142—Copolymers of propene at least partially crystalline copolymers of propene with other olefins
• • F—MECHANICAL ENGINEERING; LIGHTING; HEATING; WEAPONS; BLASTING
  • F16—ENGINEERING ELEMENTS AND UNITS; GENERAL MEASURES FOR PRODUCING AND MAINTAINING EFFECTIVE FUNCTIONING OF MACHINES OR INSTALLATIONS; THERMAL INSULATION IN GENERAL
  • F16L—PIPES; JOINTS OR FITTINGS FOR PIPES; SUPPORTS FOR PIPES, CABLES OR PROTECTIVE TUBING; MEANS FOR THERMAL INSULATION IN GENERAL
  • F16L9/00—Rigid pipes
  • F16L9/12—Rigid pipes of plastics with or without reinforcement
• • C—CHEMISTRY; METALLURGY
  • C08—ORGANIC MACROMOLECULAR COMPOUNDS; THEIR PREPARATION OR CHEMICAL WORKING-UP; COMPOSITIONS BASED THEREON
  • C08F—MACROMOLECULAR COMPOUNDS OBTAINED BY REACTIONS ONLY INVOLVING CARBON-TO-CARBON UNSATURATED BONDS
  • C08F2500/00—Characteristics or properties of obtained polyolefins; Use thereof
  • C08F2500/05—Bimodal or multimodal molecular weight distribution
• • C—CHEMISTRY; METALLURGY
  • C08—ORGANIC MACROMOLECULAR COMPOUNDS; THEIR PREPARATION OR CHEMICAL WORKING-UP; COMPOSITIONS BASED THEREON
  • C08F—MACROMOLECULAR COMPOUNDS OBTAINED BY REACTIONS ONLY INVOLVING CARBON-TO-CARBON UNSATURATED BONDS
  • C08F2500/00—Characteristics or properties of obtained polyolefins; Use thereof
  • C08F2500/12—Melt flow index or melt flow ratio
• • C—CHEMISTRY; METALLURGY
  • C08—ORGANIC MACROMOLECULAR COMPOUNDS; THEIR PREPARATION OR CHEMICAL WORKING-UP; COMPOSITIONS BASED THEREON
  • C08L—COMPOSITIONS OF MACROMOLECULAR COMPOUNDS
  • C08L2203/00—Applications
  • C08L2203/18—Applications used for pipes
• • C—CHEMISTRY; METALLURGY
  • C08—ORGANIC MACROMOLECULAR COMPOUNDS; THEIR PREPARATION OR CHEMICAL WORKING-UP; COMPOSITIONS BASED THEREON
  • C08L—COMPOSITIONS OF MACROMOLECULAR COMPOUNDS
  • C08L2205/00—Polymer mixtures characterised by other features
  • C08L2205/02—Polymer mixtures characterised by other features containing two or more polymers of the same C08L -group
• • C—CHEMISTRY; METALLURGY
  • C08—ORGANIC MACROMOLECULAR COMPOUNDS; THEIR PREPARATION OR CHEMICAL WORKING-UP; COMPOSITIONS BASED THEREON
  • C08L—COMPOSITIONS OF MACROMOLECULAR COMPOUNDS
  • C08L2205/00—Polymer mixtures characterised by other features
  • C08L2205/02—Polymer mixtures characterised by other features containing two or more polymers of the same C08L -group
  • C08L2205/025—Polymer mixtures characterised by other features containing two or more polymers of the same C08L -group containing two or more polymers of the same hierarchy C08L, and differing only in parameters such as density, comonomer content, molecular weight, structure
• • C—CHEMISTRY; METALLURGY
  • C08—ORGANIC MACROMOLECULAR COMPOUNDS; THEIR PREPARATION OR CHEMICAL WORKING-UP; COMPOSITIONS BASED THEREON
  • C08L—COMPOSITIONS OF MACROMOLECULAR COMPOUNDS
  • C08L2205/00—Polymer mixtures characterised by other features
  • C08L2205/24—Crystallisation aids
• • C—CHEMISTRY; METALLURGY
  • C08—ORGANIC MACROMOLECULAR COMPOUNDS; THEIR PREPARATION OR CHEMICAL WORKING-UP; COMPOSITIONS BASED THEREON
  • C08L—COMPOSITIONS OF MACROMOLECULAR COMPOUNDS
  • C08L2314/00—Polymer mixtures characterised by way of preparation
  • C08L2314/02—Ziegler natta catalyst

Definitions

• the present invention relates to nucleated propylene random copolymer compositions with an improved balance of properties in regard of mechanical properties including impact properties and processing properties which are suitable for pipe applications.
• Polypropylene materials are frequently used for various pipe and pipe fitting applications, such as fluid transport, e.g. water or natural gas, during which the fluid is pressurized and/or heated.
• fluid transport e.g. water or natural gas
• polypropylene materials are used in applications for plumbing and heating, such as in-house hot and cold water pressure pipes and fittings, floor and wall heating systems and radiator connections.
• propylene random copolymers are especially suitable for pressure pipe applications for hot water and industrial pipes as the random copolymers have inter alia good impact performance, stiffness, creep resistance and slow crack properties and long term pressure resistance.
• pressure pipe used herein refers to a pipe which, when used, is subjected to a positive pressure, that is the pressure inside the pipe being higher than the pressure outside the pipe.
• propylene random copolymers based pipes for hot and cold water pressure applications are often coloured e.g. Green, Grey, Blue, and White etc.
• Different pigments have different nucleation effect on propylene random copolymers and variation in intensity of the effect from one colour to another will result in dimensional variations because differences in shrinkage associated with the nucleation.
• WO0068315 ( EP1183307 ) of Borealis discloses nucleated homo polymer and heterophasic copolymer of propylene and mentions pipe as one of the numerous options of end applications. Said solution is focused on moulding applications and the examples are for homo polypropylene and heterophasic polypropylene with high melt flow rate which is not suitable for pipe applications.
• WO 99/24479 of Borealis discloses nucleated propylene polymer, however examples disclose homo polymers of propylene and heterophasic copolymers of propylene.
• the heterophasic copolymers of propylene are stated to be "stiff" (examples 9 and 10, e.g. flexural modulus of around 1500 and 1600 MPa), whereby they are suitable for sewage pipe applications.
• the present invention relates to a polypropylene composition suitable for pipe applications comprising a multimodal propylene random copolymer (A) with at least one comonomer selected from alpha-olefins with 2 or 4 to 8 carbon atoms and a nucleating agent (B), wherein the polypropylene composition has a Charpy Notched Impact Strength at 23°C of at least 30 kJ/m 2 , determined according to ISO 179/1eA:2000 using notched injection moulded specimens.
• A multimodal propylene random copolymer
• B nucleating agent
• the present invention is further characterized in that the multimodal propylene random copolymer (A) of the polypropylene composition of the invention does not contain an elastomeric phase dispersed therein.
• the polypropylene composition according to the present invention not only shows good mechanical properties in view of the flexural modulus, but also very good impact properties, as can be seen from the Charpy Notched Impact Strength at room temperature and preferably also at cold temperatures. More preferably the present multimodal polypropylene composition shows advantageously feasible creep resistance as can be seen from tensile stress. Further preferably, the present multimodal polypropylene composition has advantageous pressure resistance required for pressure pipe applications. The present multimodal polypropylene composition has preferably also an advantageous processing behavior in terms of pipe extrusion and/or cycle time of molded fittings. The obtained final pipe or fitting has a uniform shrinkage behavior and a good surface quality.
• Pressure pipe for hot and cold water applications has a well-known meaning in the field of polypropylene pipe applications and implies for a skilled person generally accepted property requirements for the pipe to be usable in such applications.
• a propylene random copolymer denotes a copolymer of propylene monomer units and comonomer units in which the comonomer units are randomly distributed in the polymeric chain.
• a propylene random copolymer includes a fraction, which is insoluble in xylene - xylene cold insoluble (XCU) fraction, in an amount of at least 70 wt%, more preferably of at least 80 wt%, still more preferably of at least 85 wt% and most preferably of at least 90 wt%, based on the total amount of the propylene random copolymer.
• the random copolymer does not contain an elastomeric polymer phase dispersed therein.
• random copolymer is different from heterophasic polypropylene which is a propylene copolymer comprising a propylene homo or random copolymer matrix component (1) and an elastomeric copolymer component (2) of propylene with one or more of ethylene and C4-C8 alpha-olefin copolymers, wherein the elastomeric (amorphous) copolymer component (2) is dispersed in said propylene homo or random copolymer matrix polymer (1).
• a propylene polymer comprising at least two propylene polymer fractions (components), which have been produced under different polymerisation conditions resulting in different (weight average) molecular weights and/or different comonomer contents for the fractions, preferably produced by polymerizing in multiple polymerization stages with different polymerization conditions, is referred to as "multimodal".
• multi relates to the number of different polymer fractions the propylene polymer is consisting of.
• a propylene polymer consisting of two fractions only is called "bimodal”
• a propylene polymer consisting of three fractions only is called "trimodal".
• the term “different” means that the propylene polymer fractions differ from each other in at least one property, preferably in the weight average molecular weight or comonomer content or both, more preferably at least in the weight average molecular weight.
• the form of the molecular weight distribution curve i.e. the appearance of the graph of the polymer weight fraction as function of its molecular weight, of such a multimodal propylene polymer is at least distinctly broadened in comparison with the curves for the individual fractions.
• the propylene random copolymer used in the present invention is a multimodal propylene random copolymer, more preferably a bimodal propylene random copolymer.
• the multimodal propylene random copolymer (A) consists of the two propylene copolymer fractions with the proviso that at least one of the two fractions, preferably both fractions are propylene random copolymer fractions.
• a propylene homopolymer thereby denotes a polymer consisting essentially of propylene monomer units. Due to the requirements of large-scale polymerization it may be possible that the propylene homopolymer includes minor amounts of comonomer units, which usually is below 0.1 mol%, preferably below 0.05 mol%, most preferably below 0.01 mol% of the propylene homopolymer.
• a nucleating agent denotes herein a compound or composition which is added on purpose to increase the crystallization rate within the solid polymer and lead to an increased degree of crystallinity (and often to a smaller crystal size) of the solid polymer.
• the multimodal propylene random copolymer (A) used in the polypropylene composition of the invention comprises at least one comonomer selected from alpha-olefins with 2 or 4 to 8 carbon atoms.
• the multimodal propylene random copolymer (A) may comprise only one type of comonomers or two or more types of comonomers.
• the comonomers of said multimodal propylene random copolymer (A) are preferably selected from C 2 and C 4 to C 6 alpha-olefins.
• a particular preferred comonomer is ethylene.
• a multimodal propylene random copolymer (A) which is a propylene random copolymer with ethylene comonomer.
• the propylene random copolymer (A) which is preferably the propylene random copolymer with ethylene comonomer, comprises at least a propylene random copolymer having a low molecular weight (low molecular weight (LMW) fraction) and a propylene random copolymer having a high molecular weight (high molecular weight (HMW) fraction).
• LMW low molecular weight
• HMW high molecular weight
• melt flow rate (MFR) of a polymer is an indication of the weight average molecular weight (Mw) of the polymer, the higher the MFR the lower the Mw of the polymer and, respectively, the lower the MFR the higher the Mw of the polymer. Accordingly, the MFR of the low molecular weight fraction is higher than the MFR of the high molecular weight fraction.
• both the low molecular weight fraction and the high molecular weight fraction are propylene random copolymer fractions which may have essentially the same or different comonomer content. It is thereby preferred that the high molecular weight fraction has an equal to higher, preferably higher, comonomer content compared to the low molecular weight fraction.
• the comonomer content of the high molecular weight fraction is usually in the range of 1.0 to 17.0 mol%, preferably 1.5 to 10.0 mol%, more preferably 3.5 to 8.5 mol%, still more preferably 5.0 to 8.0 mol, most preferably 6.0 to 7.5 mol%, based on the total content of monomeric units in the high molecular weight fraction.
• the comonomer content of the low molecular weight fraction is usually in the range of 0.1 to 11.0 mol%, preferably 1.5 to 8.5 wt%, more preferably 3.5 to 7.5 mol%, most preferably 5.0 to 6.5 mol%, based on the total content of monomeric units in the low molecular weight fraction.
• the multimodal propylene random copolymer (A) comprises at least a low molecular weight fraction (LMW fraction) and a high molecular weight fraction (HMW fraction), wherein the high molecular weight fraction (HMW fraction) has higher comonomer, preferably ethylene comonomer, content, than the low molecular weight fraction (LMW fraction).
• the comonomer preferably ethylene comonomer content of HMW fraction, is within the preferred ranges as defined above.
• the comonomer content of the multimodal propylene random copolymer (A) is usually in the range of 0.1 to 14 mol%, preferably 1.5 to 10.0 mol%, more preferably 3.5 to 8.5 mol%, still more preferably 4.0 to 7.0 mol%, most preferably 4.5 to 6.5 mol%, based on the total content of monomeric units in the multimodal propylene random copolymer (A).
• the low molecular weight fraction and the high molecular weight fraction may include the same type of comonomer or different types of comonomers. It is thereby preferred that both fractions include the same type of comonomer.
• the low molecular weight fraction is preferably present in the propylene random copolymer in an amount of 35 to 55 wt%, more preferably in an amount of 40 to 50 wt% and most preferably in an amount of 40 to 47 wt%, based on the total amount of the propylene random copolymer (100wt%), preferably, and the high molecular weight fraction is preferably present in the propylene random copolymer in an amount of 65 to 45 wt%, more preferably in an amount of 60 to 50 wt% and most preferably in an amount of 60 to 53 wt%, based on the total amount of the propylene random copolymer (100wt%).
• the multimodal propylene random copolymer (A) preferably has a density of 890 to 910, preferably 895 to 905 kg/m 3 .
• the propylene random copolymer (A) consists of the propylene random copolymer having a low molecular weight (low molecular weight (LMW) fraction), the propylene random copolymer having a high molecular weight (high molecular weight (HMW) fraction), the nucleating agent (B) and optional further additives, as defined above or below.
• LMW low molecular weight
• HMW high molecular weight
• the multimodal propylene random copolymer (A) may further comprise a prepolymer fraction.
• a prepolymer fraction In case of the presence of a prepolymer fraction, said fraction is calculated to the amount (wt%) of the low molecular weight fraction or high molecular weight fraction, preferably to the amount of high molecular weight fraction.
• the prepolymer fraction can be propylene homopolymer or copolymer.
• polypropylene composition according to the invention consists of the propylene random copolymer (A), the nucleating agent (B) and optional further additives, as defined above or below.
• the amount of the multimodal propylene random copolymer (A) is preferably 90.0 to 99.75 wt%, more preferably of 95.0 to 99.75 wt% and even more preferably of 96.5 to 99.75 wt%, based on the total weight of the polypropylene composition (100 wt%).
• the nucleating agent (B) used in the polypropylene composition of the invention is preferably selected from
• nucleating agent (B) is other than beta-nucleating agent, which term is well known in the art.
• said nucleating agent (B) is a polymeric nucleating agent, preferably a polymer of vinyl compound, more preferably a polymeric nucleating agent obtainable by polymerising vinylcycloalkane monomers or vinylalkane monomers.
• nucleating agent (B) is selected from: vinyl cycloalkane polymer, preferably vinyl cyclohexane (VCH) polymer, vinyl cyclopentane polymer, 3-methyl-1-butene polymer and vinyl-2-methyl cyclohexane polymer.
• the most preferred nucleating agent (B) is vinyl cyclohexane (VCH) polymer.
• nucleating agent (B) is a polymeric nucleating agent, more preferably a polymer of vinyl compound according to formula (I) as defined above, even more preferably vinyl cyclohexane (VCH) polymer.
• the amount of nucleating agent (B) preferably is not more than 10000 ppm by weight (means parts per million based on the total weight of the polypropylene composition (100 wt%), preferably based on the combined weight of propylene random copolymer (A) and nucleating agent (B), also abbreviated herein shortly as ppm), more preferably not more than 6000 ppm, even more preferably not more than 5000 ppm, based on the total weight of the polypropylene composition (100 wt%), preferably based on the combined weight of propylene random copolymer (A) and nucleating agent (B).
• the amount of the nucleating agent (B) still more preferably is not more than 500 ppm, preferably is from 0.025 to 200 ppm, and more preferably is from 0.1 to 200 ppm, more preferably is from 0.3 to 200 ppm, most preferably is from 0.3 to 100 ppm, based on the total weight of the polypropylene composition (100 wt%), preferably based on the combined weight of propylene random copolymer (A) and nucleating agent (B).
• the nucleating agent (B) is a polymeric nucleating agent, most preferably a polymer of vinyl compound according to formula (I) as defined above, even more preferably vinyl cyclohexane (VCH) polymer as defined above, and the amount of said nucleating agent (B) is not more than 500 ppm, more preferably is from 0.025 to 200 ppm, and more preferably is from 0.1 to 200 ppm, more preferably is from 0.3 to 200 ppm, most preferably is from 0.3 to 100 ppm, based on the total weight of the polypropylene composition (100 wt%), preferably based on the combined weight of propylene random copolymer (A) and nucleating agent (B).
• VCH vinyl cyclohexane
• the nucleating agent (B) may be introduced to the multimodal propylene random copolymer (A) e.g. during the polymerisation process of the multimodal propylene random copolymer (A) or may be incorporated to the multimodal propylene random copolymer (A) in the form of masterbatch (MB) together with e.g. a carrier polymer. It is preferred that the nucleating agent (B) is introduced to the multimodal propylene random copolymer (A) during the polymerisation process of the multimodal propylene random copolymer (A).
• the nucleating agent (B) is preferably introduced to the multimodal propylene random copolymer (A) by first polymerising the above defined vinyl compound according to formula (I) as defined above, even more preferably vinyl cyclohexane (VCH), in the presence of a catalyst system comprising a solid catalyst component, preferably a solid Ziegler Natta catalyst component, a cocatalyst and optional external donor, and the obtained reaction mixture of the polymer of the vinyl compound according to formula (I) as defined above, even more preferably vinyl cyclohexane (VCH) polymer, and the catalyst system is then used for producing the multimodal propylene random copolymer (A).
• a catalyst system comprising a solid catalyst component, preferably a solid Ziegler Natta catalyst component, a cocatalyst and optional external donor
• VHC vinyl cyclohexane
• the propylene composition of the invention may contain further additives suitable for pipe applications, preferably conventional additives for pipe applications, in addition to the nucleating agent (B), including without limiting to, further nucleating agents, clarifiers, brighteners, acid scavengers and antioxidants, as well as slip agents, inorganic filler and UV light stabilizers.
• Each additive can be used e.g. in conventional amounts, the total amount of additives present in the propylene composition being preferably as defined below.
• Such additives are generally commercially available and are described, for example, in " Plastic Additives Handbook", 5th edition, 2001 of Hans Zweifel .
• the total amount of optional further additives is preferably between 0.0001 and 10 wt%, preferably 0.0001 and 5.0 wt%, preferably 0.0001 and 2.5 wt%, more preferably between 0.0001 and 1.5 wt%, still more preferably between 0.0001 and 1.0 wt%, based on the total weight of the polypropylene composition (100 wt%).
• the carrier material, e.g. carrier polymer, of the additive is calculated to the (total) amount of the additive(s), based on the total weight of the polypropylene composition (100 wt%).
• polypropylene composition according to the invention consists of the multimodal propylene random copolymer (A), the nucleating agent (B) and optional additives, all as defined above.
• the polypropylene composition preferably has a melt flow rate MFR 2 (2.16 kg, 230°C) of 0.1 to 1.0 g/10 min, more preferably 0.1 to 0.7 g/10 min, more preferably 0.15 to 0.5 g/10 min, more preferably 0.2 to 0.4 g/10 min, determined according to ISO 1133.
• the polypropylene composition preferably has a content of xylene cold solubles (XCS) of 1 to 15 wt%, more preferably of 2 to 12 wt%, most preferably of 4 to 10 wt%, determined at 25°C according to ISO 16152. Still further, the polypropylene composition preferably has a crystallization temperature of 105°C to 130°C, more preferably of 107°C to 127°C, most preferably of 110°C to 125°C, even most preferably of 110°C to 120°C.
• XCS xylene cold solubles
• the polypropylene composition has a polydispersity index PI of from 2.0 to 6.0, preferably of from 2.5 to 5.5, more preferably of from 3.0 to 5.0 and most preferably of from 3.2 to 4.5.
• the polydispersity index is determined from rheological measurements as described below in the example section.
• the polypropylene composition has a Charpy Notched Impact Strength at room temperature (23°C) of from 35 to 100 kJ/m 3 , more preferably from 37 to 80 kJ/m 3 , most preferably from 38 to 70 kJ/m 3 .
• the Charpy Notched Impact Strength at cold temperatures (0°C, -20°C) is very advantageous.
• the polypropylene composition preferably has a flexural modulus of at least 700 MPa, more preferably at least 750 MPa, more preferably at least 800 MPa, more preferably at least 850 MPa, determined according to ISO 178 at a test speed of 2mm/min and a force of 100N on test specimens having a dimension of 80x10x4.0 mm 3 (length x width x thickness) prepared by injection moulding according to EN ISO 1873-2.
• the upper limit of the flexural modulus usually does not exceed 1400 MPa, and is preferably 1200 MPa or less.
• the polypropylene composition preferably has a tensile stress at yield of at least 20 MPa, more preferably at least 25 MPa, most preferably at least 27 MPa, determined according to ISO 527-2:1996 using type 1A injection moulded test specimens prepared according to ISO 527-2:1996.
• the upper limit of the tensile stress at yield usually does not exceed 50 MPa and is preferably not higher than 45 MPa.
• the shrinkage of the polypropylene composition after forming the composition into an article, preferably a pipe or a pipe fitting, is preferably not more than 6%, more preferably not more than 5 %, most preferably not
• the polypropylene composition of the invention is preferably produced in a continuous multistage process in a conventional manner. It is to be understood that as soon as the inventors have found the advantageous property balance resulting to the polypropylene composition, then for industrial scale production it is within the skills of a skilled person to adjust process parameters and controls to obtain the properties of the polypropylene composition.
• the process preferably comprises at least two polymerisation stages.
• process according to the present invention includes the following process steps:
• a combination of slurry (or bulk) and at least one gas phase reactor is often preferred for the polymerisation of the multimodal propylene random copolymer (A). It is further preferred that the reactor order is slurry (or bulk) then one or more gas phase reactors.
• the reaction temperature will generally be in the range 60 to 110°C, e.g. 60 to 85 °C
• the reactor pressure will generally be in the range 5 to 80 bar, e.g. 20 to 60 bar
• the residence time will generally be in the range 0.1 to 5 hours, e.g. 0.3 to 2 hours.
• the monomer is usually used as reaction medium.
• the reaction temperature used will generally be in the range 60 to 115 °C, e.g. 70 to 110 °C
• the reactor pressure will generally be in the range 10 to 25 bar
• the residence time will generally be 0.5 to 8 hours, e.g. 0.5 to 4 hours.
• the gas used will be the monomer optionally as mixture with a non-reactive gas such as nitrogen or propane.
• the process can contain any additional polymerisation steps, like prepolymerisation step, and any further after reactor handling steps as known in the art.
• the multimodal propylene random copolymer (A) is produced in a sequential polymerization process comprising at least two polymerization zones operating at different conditions to produce the multimodal propylene random copolymer (A).
• the polymerization zones may operate in slurry, solution, or gas phase conditions or their combinations. Suitable processes are disclosed, among others, in WO-A-98/58975 , WO-A-98/58976 , EP-A-887380 and WO-A-98/58977 .
• the optional prepolymerization is conducted in a continuous manner as bulk slurry polymerization in liquid propylene, i.e. the liquid phase mainly comprises propylene, with minor amount of other reactants and optionally inert components dissolved therein.
• the prepolymerization is conducted in a continuous stirred tank reactor or a loop reactor.
• the prepolymerization reaction is typically conducted at a temperature of 0 to 60 °C, preferably from 10 to 50 °C, and more preferably from 20 to 45 °C.
• the pressure in the prepolymerization reactor is not critical but must be sufficiently high to maintain the reaction mixture in liquid phase.
• the pressure may be from 20 to 100 bar, for example 30 to 70 bar.
• reaction conditions are well known in the art as disclosed, among others, in GB 1580635 .
• the polymerization in the first polymerization zone may be conducted in slurry. Then the polymer particles formed in the polymerization, together with the catalyst fragmented and dispersed within the particles, are suspended in the fluid hydrocarbon. The slurry is agitated to enable the transfer of reactants from the fluid into the particles.
• Slurry polymerization is preferably a so called bulk polymerization.
• bulk polymerization is meant a process where the polymerization is conducted in a liquid monomer essentially in the absence of an inert diluent.
• the temperature in the slurry polymerization is typically from 50 to 110 °C, preferably from 60 to 100 °C and in particular from 60 to 80 °C.
• the pressure is from 1 to 150 bar, preferably from 10 to 100 bar, most preferably from 30 to 65 bar.
• Such reaction conditions are often referred to as "supercritical conditions”.
• the phrase "supercritical fluid” is used to denote a fluid or fluid mixture at a temperature and pressure exceeding the critical temperature and pressure of said fluid or fluid mixture.
• the slurry polymerization may be conducted in any known reactor used for slurry polymerization.
• reactors include a continuous stirred tank reactor and a loop reactor. It is especially preferred to conduct the polymerization in loop reactor.
• the slurry is circulated with a high velocity along a closed pipe by using a circulation pump.
• Loop reactors are generally known in the art and examples are given, for instance, in US 4,582,816 , US 3,405,109 , US 3,324,093 , EP-A-479186 and US 5,391,654 .
• the polymerization in gas phase may be conducted in a fluidized bed reactor, in a fast fluidized bed reactor or in a settled bed reactor or in any combination of these.
• a combination of reactors is used then the polymer is transferred from one polymerization reactor to another.
• a part or whole of the polymer from a polymerization stage may be returned into a prior polymerization stage.
• the fluidized bed polymerization reactor is operated at a temperature within the range of from 50 to 100 °C, preferably from 70 to 90 °C.
• the pressure is suitably from 10 to 40 bar, preferably from 10 to 30 bar.
• the adjustment of the melt flow rate during the polymerisation process of multimodal propylene random copolymer (A) is carried out in a conventional manner by using e.g. a chain termination agent (known also e.g. as molecular weight of MFR controlling agent), typically hydrogen.
• a chain termination agent known also e.g. as molecular weight of MFR controlling agent
• the preferred multistage process is carried out in a reactor system comprising at least a loop reactor, and optionally one, two or more gas phase reactors, in said order.
• Said reactor system and process is known as Borstar ® Technology.
• Especially preferred for the polymerization of the multimodal propylene random copolymer (A) is a reactor assembly consisting of a loop reactor followed by a gas phase reactor.
• the loop reactor is thereby optionally preceded by a prepolymerization reactor which may also be a slurry reactor.
• a copolymer mixture comprising the copolymer produced in loop reactor and a copolymer produced in the gas phase reactor is formed.
• the copolymer mixture is formed by introducing the particles of the copolymer of the loop reactor, containing active catalyst dispersed therein, together with additional propylene and comonomer, into the polymerization in gasphase reactor. This causes the copolymer produced in gas phase reactor to form on the particles containing the copolymer of the loop reactor.
• Said first propylene random copolymer preferably reflects the propylene random copolymer having a high molecular weight (HMW) fraction of the propylene random copolymer (A) and said second propylene random copolymer preferably reflects the low molecular weight (LMW) fraction of the propylene random copolymer (A) as defined above.
• copolymer mixture comprising the first propylene random copolymer and a second propylene random copolymer preferably reflects a mixture of the high molecular weight (HMW) fraction and the low molecular weight (LMW) fraction of the propylene random copolymer (A) as defined above.
• the amount of any prepolymer fraction thereby preferably adds to the amount of the high molecular weight fraction.
• the multimodal propylene random copolymer (A) can be produced by polymerisation in the presence of any conventional coordination catalyst system including Ziegler-Natta, chromium and single site (like metallocene catalyst), preferably in the presence of a Ziegler-Natta catalyst system.
• a Ziegler-Natta catalyst system typically comprises a solid catalyst component, preferably a solid transition metal component, and a cocatalyst, and optionally an external donor.
• the solid catalyst component comprises most preferably a magnesium halide, a titanium halide and an internal electron donor.
• Such catalysts are well known in the art.
• nucleating agent (B) is introduced to the multimodal propylene random copolymer (A) during the polymerisation process of the propylene random copolymer (A).
• nucleating agent (B) is introduced together with the solid Ziegler-Natta catalyst system for the polymerisation of the multimodal propylene random copolymer (A).
• a vinyl compound of the formula (I) as defined above or below is polymerised in the presence of a catalyst system comprising the solid catalyst component, preferably a solid Ziegler Natta catalyst component, to obtain a modified catalyst system which is the reaction mixture comprising the solid catalyst component and the produced polymer of the vinyl compound of formula (I).
• a catalyst system comprising the solid catalyst component, preferably a solid Ziegler Natta catalyst component
• the weight ratio (g) of the polymer of the vinyl compound of the formula (I), to the solid catalyst component is preferably up to 5 (5:1), preferably up to 3 (3:1) most preferably is from 0.5 (1:2) to 2 (2:1).
• the obtained modified catalyst system is then used for the polymerisation of the propylene random copolymer (A) of the invention.
• said catalyst component comprises preferably a transition metal component and a magnesium halide.
• These compounds may be supported on a particulate support, such as inorganic oxide, like silica or alumina, or, usually, the magnesium halide to form above said solid support.
• a particulate support such as inorganic oxide, like silica or alumina, or, usually, the magnesium halide to form above said solid support.
• examples of such solid catalyst components are disclosed, among others, in WO 87/07620 , WO 92/21705 , WO 93/11165 , WO 93/11166 , WO 93/19100 , WO 97/36939 , WO 98/12234 , WO 99/33842 .
• the solid catalyst components for polymerising the multimodal propylene random copolymer (A) typically comprise, in addition to the magnesium halide and transition metal compound, an electron donor (internal electron donor).
• Suitable electron donors are, among others, esters of carboxylic acids, like phthalates, citraconates, and succinates. Also oxygen- or nitrogen-containing silicon compounds may be used. Examples of suitable compounds are shown in WO 92/19659 , WO 92/19653 , WO 92/19658 , US 4,347,160 , US 4,382,019 , US 4,435,550 , US 4,465,782 , US 4,473,660 , US 4,530,912 and US 4,560,671 .
• said solid catalyst components are preferably used in combination with well known external electron donors, including without limiting to, ethers, ketones, amines, alcohols, phenols, phosphines and silanes, for example organosilane compounds containing Si-OCOR, Si-OR, or Si-NR 2 bonds, having silicon as the central atom, and R is an alkyl, alkenyl, aryl, arylalkyl or cycloalkyl with 1-20 carbon atoms; and well known cocatalysts, which preferably comprise an aluminium alkyl compound as known in the art, to polymerise the propylene random copolymer (A).
• well known external electron donors including without limiting to, ethers, ketones, amines, alcohols, phenols, phosphines and silanes, for example organosilane compounds containing Si-OCOR, Si-OR, or Si-NR 2 bonds, having silicon as the central atom, and R is an alkyl, alken
• the amount of nucleating agent (B) present in the multimodal propylene random copolymer (A) is preferably not more than 500 ppm, more preferably is 0.025 to 200 ppm, still more preferably is 1 to 100 ppm, and most preferably is 5 to 100 ppm, based on the multimodal propylene random copolymer (A) and the nucleating agent (B), preferably based on the total weight of the propylene composition (100 wt%).
• the polymer When the polymer has been removed from the last polymerisation stage, it is preferably subjected to process steps for removing the residual hydrocarbons from the polymer. Such processes are well known in the art and can include pressure reduction steps, purging steps, stripping steps, extraction steps and so on. Also combinations of different steps are possible.
• the second propylene copolymer composition is preferably mixed with additives as it is well known in the art. Such additives include antioxidants, process stabilizers, neutralisers, lubricating agents, nucleating agents, pigments and so on.
• additives include antioxidants, process stabilizers, neutralisers, lubricating agents, nucleating agents, pigments and so on.
• the polymer particles are then extruded to pellets as it is known in the art.
• co-rotating twin screw extruder is used for the extrusion step.
• extruders are manufactured, for instance, by Coperion (Werner & Pfleiderer) and Japan Steel Works.
• the present invention relates to an article comprising the multimodal polypropylene composition according to the present invention.
• the article is selected from an extruded article, preferably a pipe application, or a moulded article, preferably an injection moulded or blow moulded article, application more preferably a fitting for pipe applications, comprising the multimodal polypropylene composition of the invention.
• the pipe and fitting produced from the polypropylene composition according to the invention preferably has good mechanical properties as described above and shown below in experimental part.
• the pipe according to the invention preferably qualifies as pressure pipe.
• Pipe of the invention can be a monolayer pipe, wherein the pipe layer comprises, preferably consists of, the multimodal polypropylene composition of the invention, or -a multilayer pipe, wherein at least one layer comprises, preferably consists of, the multimodal polypropylene composition of the invention.
• the preferred pipe of the invention has at least one layer comprising, preferably consisting of, the multimodal polypropylene composition of the invention.
• Preferred pipe is a pressure pipe, more preferably a pressure pipe for hot and cold water applications.
• Fitting of the invention preferably consists of the multimodal polypropylene composition of the invention.
• Pipes can be produced from the multimodal polypropylene composition according to the present invention according to the methods known in the art.
• the multimodal polypropylene composition is extruded through an annular die to a desired internal diameter, after which the multimodal polypropylene composition is cooled.
• the pipe extruder preferably operates at a relatively low temperature and therefore excessive heat build-up should be avoided.
• Extruders having a high length to diameter ratio L/D more than 15, preferably of at least 20 and in particular of at least 25 are preferred.
• the modern extruders typically have an L/D ratio of from about 30 to 35.
• the polymer melt is extruded through an annular die, which may be arranged either as end-fed or side-fed configuration.
• the side-fed dies are often mounted with their axis parallel to that of the extruder, requiring a right-angle turn in the connection to the extruder.
• the advantage of side-fed dies is that the mandrel can be extended through the die and this allows, for instance, easy access for cooling water piping to the mandrel.
• the extrudate is directed into a metal tube (calibration sleeve).
• the inside of the extrudate is pressurised so that the plastic is pressed against the wall of the tube.
• the extrudate leaving the die is directed into a tube having a perforated section in the centre.
• a slight vacuum is drawn through the perforation to hold the pipe against the walls of the sizing chamber.
• Fittings of the invention can be produced from the multimodal polypropylene composition according to the present invention using the methods and equipment known in the art.
• the multimodal polypropylene composition is moulded, preferably injection moulded or blown moulded, more preferably injection moulded, in a conventional manner using conventional moulding equipment, to a shape of a fitting for a pipe.
• the melt flow rate is determined according to ISO 1133 and is indicated in g/10 min.
• the MFR is an indication of the flowability, and hence the processability, of the polymer. The higher the melt flow rate, the lower the viscosity of the polymer.
• the MFR 10 of polypropylene is measured at a temperature 230 °C and a load of 10 kg, the MFR 2 of polypropylene at a temperature 230 °C and a load of 2.16 kg.
• the quantity FRR (flow rate ratio) denotes the ratio of flow rates at different loads.
• FRR 10/2 denotes the ratio of MFR 10 /MFR 2 .
• MI melt index MFR 2
• subscripts b, 1 and 2 refer to the mixture, component 1 and component 2, respectively.
• Density of the polymer was measured according to ISO 1183-1:2004 Method A on compression moulded specimen prepared according to EN ISO 1872-2(February 2007) and is given in kg/m 3 .
• the comonomer content was determined by quantitative Fourier transform infrared spectroscopy (FTIR) after basic assignment calibrated via quantitative 13 C nuclear magnetic resonance (NMR) spectroscopy in a manner well known in the art. Thin films are pressed to a thickness of between 100-500 micrmeter and spectra recorded in transmission mode.
• FTIR quantitative Fourier transform infrared spectroscopy
• NMR quantitative 13 C nuclear magnetic resonance
• the ethylene content of a polypropylene-co-ethylene copolymer is determined using the baseline corrected peak area of the quantitative bands found at 720-722 and 730-733 cm -1 .
• the butene or hexene content of a polypropylene copolymer is determined using the baseline corrected peak area of the quantitative bands found at 1377-1379 cm -1 . Quantitative results are obtained based upon reference to the film thickness.
• C is the content of comonomer in weight-%
• w is the weight fraction of the component in the mixture
• subscripts b, 1 and 2 refer to the overall mixture, component 1 and component 2, respectively.
• c m is the mole fraction of comonomer units in the copolymer
• c w is the weight fraction of comonomer units in the copolymer
• MW c is the molecular weight of the comonomer (such as ethylene)
• MW m is the molecular weight of the main monomer (i.e., propylene).
• Xylene cold solubles (XCS, wt.-%) content was determined at 25 °C according ISO 16152; first edition; 2005-07-01.
• XS b w 1 ⁇ XS 1 + w 2 ⁇ XS 2
• XS is the content of xylene soluble polymer in weight-%
• w is the weight fraction of the component in the mixture
• subscripts b, 1 and 2 refer to the overall mixture, component 1 and component 2, respectively.
• the flexural modulus was determined according to ISO 178.
• the test specimens having a dimension of 80 x 10 x 4.0 mm 3 (length x width x thickness) were prepared by injection molding according to EN ISO 1873-2.
• the length of the span between the supports was 64 mm, the test speed was 2 mm/min and the force was 100 N.
• Tensile stress at yield and tensile strain at yield was determined according to ISO 527-1:1996 and ISO 527-2:1996 on test specimen ISO 527-2:1996 type 1A molded specimen, the Injection moulding carried out according to ISO 1873-2:2007.
• Charpy notched impact strength was determined according to ISO 179-1:2000 on notched specimen of 80x10x4mm, cut from test specimen ISO 527-2:1996 type 1A. Notched impact specimen according to ISO 179-1/1eA:2000 was used. Testing temperature is 23 ⁇ 2°C. Injection moulding was carried out according to ISO 1873-2:2007.
• the crystallization temperature T c was measured with a Mettler TA820 differential scanning calorimetry device (DSC) on 3 ⁇ 0.5 mg samples according to ISO 11357-3:1999. Crystallization temperature was obtained during 10 °C/min cooling and heating scans between 30 °C and 225 °C. The crystallization temperatures were taken as the peaks of the exotherms of said peaks.
• the characterization of polymer melts by dynamic shear measurements complies with ISO standards 6721-1 and 6721-10.
• the measurements were performed on an Anton Paar MCR501 stress controlled rotational rheometer, equipped with a 25 mm parallel plate geometry. Measurements were undertaken on compression moulded plates, using nitrogen atmosphere and setting a strain within the linear viscoelastic regime. The oscillatory shear tests were done at T 190°C applying a frequency range between 0.01 and 600 rad/s and setting a gap of 1.3 mm.
• the polydispersity index, PI is defined by equation 9.
• PI 10 5 G ⁇ ⁇ COP
• ⁇ COP is the cross-over angular frequency, determined as the angular frequency for which the storage modulus, G' equals the loss modulus, G".
• 0.1 mol of MgCl 2 x 3 EtOH was suspended under inert conditions in 250 ml of decane in a reactor at atmospheric pressure.
• the solution was cooled to the temperature of -15°C and 300 ml of cold TiCl 4 was added while maintaining the temperature at said level.
• the temperature of the slurry was increased slowly to 20 °C.
• 0.02 mol of diethylhexylphthalate (DOP) was added to the slurry. After the addition of the phthalate, the temperature was raised to 135 °C during 90 minutes and the slurry was allowed to stand for 60 minutes. Then, another 300 ml of TiCl 4 was added and the temperature was kept at 135 °C for 120 minutes.
• DOP diethylhexylphthalate
• the slurry from the prepolymerization stage was directly fed to a loop reactor. Propylene, hydrogen and ethylene were further added to the loop reactor.
• the polymerization conditions and feeds are listed in Table 1.
• the slurry from loop reactor was introduced to a gas phase reactor via direct feed line, i.e. without monomer flashing in-between the reactors.
• Propylene, ethylene and hydrogen were fed to the gas phase reactor.
• the polymerization conditions and feeds are listed in Table 1.
• the final Poly-VCH content in the obtained final polymers of Examples Ex.1-3 was 200 ppm or less.
• polypropylene resins of Examples Ex1-3 and Reference Example Ref4 emerging from the gas phase reactor were compounded together with conventional antioxidants and Ca-stearate (same amounts were used for Examples Ex1-3 and Ref.4) and pelletized in a W&P ZSK 70 twin-screw extruder (Coperion) at a melt temperature of 240°C and an extruder throughput of 200 kg/h.
• C2 content refers to the ethylene comonomer content
• C3 refer to the propylene monomer feed.
• Fittings of 110 mm diameter were prepared from the polymer composition of Examples Ex1 and Ex2 and Reference Examples Ref1, Ref2 and Ref3 using the same injection moulding device and processing set up/conditions.
• the cycle time for producing fittings of Examples Ex1 and Ex2 was reduced 20% compared to cycle time for producing fittings of Ref1, Ref2 and Ref3.
• Table 2 Pipe extrusion conditions and processing properties of Examples Ex1-3 and Reference Example Ref4 Ex1 Ex2 Ex3 Ref4 Extrusion Conditions Torque [%] 45 38 40 40 Screw speed [rpm] 43.0 47.1 46.8 46.6 Extruder output [kg/h] 33 33 33 33 33 Pipe weight [g/m] 270 270 273 273 Extruder speed [m/min] 2 2 2 2 Vacuum pressure [bar] 0.38 0.38 0.38 0.38 Processing Pipe diameter [mm] 32.3 32.3 32.3 32.3 Pipe wall thickness [mm] 3 3 3 3 3 Pipe shrinkage [%] 3.3 3.3 3.15 3.0 Surface appearance ++ ++ ++ + ++ means very good in visual inspection + means good in visual inspection
• Fittings of 110 mm diameter were prepared from the polymer composition of Examples Ex1-3 and Ref.4 using the same injection moulding device and processing set up/conditions. The cycle time for producing fittings of Examples Ex.1-3 was reduced 20% compared to cycle time for producing fittings of Ref4.
• Table 3 Mechanical and thermal properties of Examples Ex1-3 and Reference Example Ref4 Ex1 Ex2 Ex3 Ref4 MFR 2 (pellets) [g/10 min] 0.23 0.23 0.27 0.29 PI 4.1 3.5 3.3 n.d. Flexural modulus [MPa] 1078 987 968 964 Charpy NIS, 23°C [kJ/m 2 ] 41.1 40.4 39.4 24.3 Ten. Stress (yield) [MPa] 30.8 28.8 28.5 28.8 Ten. Strain (yield) [%] 12.8 12.8 12.9 12.7 Tc [°C] 114.8 113.9 115.0 100.5 n.d. not determined

Landscapes

• Chemical & Material Sciences (AREA)
• Organic Chemistry (AREA)
• Health & Medical Sciences (AREA)
• Chemical Kinetics & Catalysis (AREA)
• Medicinal Chemistry (AREA)
• Polymers & Plastics (AREA)
• Engineering & Computer Science (AREA)
• General Engineering & Computer Science (AREA)
• Crystallography & Structural Chemistry (AREA)
• Mechanical Engineering (AREA)
• Materials Engineering (AREA)
• Addition Polymer Or Copolymer, Post-Treatments, Or Chemical Modifications (AREA)
• Compositions Of Macromolecular Compounds (AREA)

Priority Applications (12)

Applications Claiming Priority (1)

Publications (1)

Family

ID=48190039

Family Applications (2)

Family Applications After (1)

Country Status (10)

Cited By (3)

Families Citing this family (4)

Citations (33)

Family Cites Families (7)

• 2013
  • 2013-04-22 EP EP13002103.3A patent/EP2796502A1/fr not_active Withdrawn
• 2014
  • 2014-04-22 KR KR1020177020639A patent/KR102084122B1/ko active IP Right Grant
  • 2014-04-22 EP EP14719243.9A patent/EP2989158B1/fr active Active
  • 2014-04-22 CN CN201480022884.9A patent/CN105229074B/zh active Active
  • 2014-04-22 WO PCT/EP2014/001073 patent/WO2014173534A1/fr active Application Filing
  • 2014-04-22 US US14/786,482 patent/US10961376B2/en active Active
  • 2014-04-22 KR KR1020157032785A patent/KR101780751B1/ko active IP Right Grant
  • 2014-04-22 RU RU2015142818A patent/RU2629937C2/ru active
  • 2014-04-22 PL PL14719243T patent/PL2989158T3/pl unknown
  • 2014-04-22 SG SG11201508080YA patent/SG11201508080YA/en unknown
  • 2014-04-22 BR BR112015026921-4A patent/BR112015026921B1/pt active IP Right Grant
  • 2014-04-22 AU AU2014256449A patent/AU2014256449B2/en active Active

Patent Citations (37)

Non-Patent Citations (4)

Also Published As

Similar Documents

Legal Events